Airfoil batts for air intake of a compressor housing

ABSTRACT

The present disclosure is directed to a housing for an air compressor system. A vent region is associated with the housing to permit cooling air flow to enter and attenuate noise output from the housing. A batt carrier is positioned proximate the vent region. A plurality of airfoil shaped batts are positioned within the batt carrier to reduce airflow turbulence and provide sound suppression capability.

TECHNICAL FIELD

The present application generally relates to a housing for an air compressor and more particularly, but not exclusively, to a housing having airfoil shaped batts positioned in an air intake to increase cooling airflow into the housing and reduce noise emanating therefrom.

BACKGROUND

Industrial compressor systems are configured to produce large volumes of pressurized working fluid such as compressed air or the like. Some compressor systems are located in a container housing to prevent unauthorized access thereto. Such housings are designed to permit cooling airflow to enter the internal region while at the same time minimize external noise from projecting externally therefrom. Some existing compressor housings have various shortcomings relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.

SUMMARY

One embodiment of the present application is a unique housing for industrial air compressor systems. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for industrial systems with a unique housing having an air intake with airfoil shaped balls. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of an exemplary compressor system according to one embodiment of the present disclosure;

FIG. 2 is a perspective view of an exemplary housing for a compressor system;

FIG. 3 is a perspective view of a prior art batt inlet carrier associated with the housing of FIG. 2; and

FIG. 4 is a perspective view of a batt inlet carrier according to one exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

For the purposes of promoting an understanding of the principles of the application, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the application is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the application as described herein are contemplated as would normally occur to one skilled in the art to which the application relates.

Industrial compressor systems can be designed with large variations in size and power. In certain applications, a housing or enclosure may be used to enclose the compressor system to prevent unauthorized access to the machinery. The housing can be designed to permit cooling airflow to enter through one or more walls. The inlet conduits that permit air to enter into the internal region of the housing also permit noise to exit therefrom. The present disclosure provides for a housing that facilitates cooling flow to enter the housing with lower pressure drop than prior art systems and simultaneously reduce noise emitted therefrom. The compressor housing of the present disclosure can be designed for any type or size of industrial compressor systems including those requiring additional external components such as heat exchangers, filters, separators and the like.

Referring now to FIG. 1, an exemplary compressor system 10 that may be used with an embodiment of the present disclosure is shown therein. The compressor system 10 can include a primary motive source 20 such as an electric motor, an internal combustion engine or a fluid-driven turbine and the like. The compressor system 10 can include a compressor 30 with multi-stage compression and in the exemplary embodiment includes a first stage compressor 32, a second stage compressor 34, and a third stage compressor 36. In other embodiments a different number of compressor stages may be employed with the compressor 30.

The compressor 30 can include centrifugal, screw, axial and/or other positive displacement compression means. The primary motive source 20 is operable for driving the compressor 30 via a drive shaft 22 to compress fluids such as air or the like. A structural base 12 is configured to support at least portions of the compressor system 10 on a support surface 13 such as a floor of a housing or the like. One or more cantilevered extensions or arms 14 can extend from the base 12 and is configured to hold portions of the compressor system 10 suspended above the support surface 13. Portions of the compressed air discharged from the compressor 30 can be transported through more one or more conduits 40, 50, 60, 70 and 80 to one or more intercoolers 100 and/or to another compressor stage. An inlet fluid manifold 90 and an outlet fluid manifold 92 can be fluidly connected to the intercoolers 100 to provide cooling fluid such as water or other liquid coolant to cool the compressed air after discharge from one or more of the compressor stages of the compressor 30. The compressor system 10 can also include a controller 110 operable for controlling the primary motive power source and various valving and fluid control mechanisms (not shown) between the compressor 30 and intercoolers 100.

Referring to FIG. 2, an exemplary view of a housing 150 for holding the compressor system 10 there within. The housing 150 can include a base 152 for the compressor system 10 to rest thereon. The housing 150 can also include a top wall 154, first and second side walls 156, 158, respectively, a forward wall 160 and an aft wall 162. In some forms a cooling fan 164 can be disposed within or adjacent the aft wall 162. It should be understood that the cooling fan 164 can also be located in other positions such as adjacent one of the first and second side walls 156, 158 or the top wall 154. In other forms, the housing 150 may be constructed with a different number of walls with various angles and shapes including portions that do not conform with a typical construction as shown in FIG. 2.

The forward wall 160 can include a vent region 166 to permit cooling air flow illustrated by arrows 168 to enter into the internal region of the housing 150 to cool the compressor system therein. The vent region 166 is illustrated as extending only partially along the forward wall 160, however the vent region may extend along the entire height of the housing in some embodiments. Noise represented by arrows 170 can emanate from inside the housing 150 due to high velocity air flow 168 flowing through the vent region 166 as well as noise from operation of the compressor system 10.

Referring now to FIG. 3, a prior art vent region 166 is illustrated therein. The vent region 166 can include a batt carrier 180 configured to include a plurality of batt receiver slots 182 positioned along opposing side walls 183 thereof. The batt receiver slots 182 are configured to receive and hold one or more brick shaped batts 184 in a desired position. The brick shaped batts 184 can be installed into the receiver slots 182 to reduce noise transmitted externally. The batts 184 can be aligned in a first column 185 and a second column 187 as illustrated. Each brick shaped batt 184 is a rectangular brick like structure that includes a top side 186 extending between a first end 188 and a second end 190 along a longitudinal length and between a first side 192 and a second side 194 extending in a lateral direction. An opposing bottom wall 196 is located opposite the top wall 186. A space 189 is formed between each of the brick shaped batts 184 so as to provide a pathway for cooling air to flow therethrough.

Referring now to FIG. 4, an exemplary batt carrier 200 according to one embodiment of the present disclosure is illustrated. The batt carrier 200 includes a plurality of slots 202 extending along a length of opposing side walls 203 from a top wall 205 to a bottom wall 207. The plurality of slots 202 can include a top guide rail 204 and a bottom guide rail 206 to hold one or more airfoil batts 210. The airfoil batts 210 are shaped as an airfoil to minimize downstream turbulence in the air flow streamlines 224 entering the housing 150 so as to reduce noise generated by turbulent flow. Each airfoil batt 210 includes a leading edge 212 having a relatively large radius rounded nose portion and a trailing edge 214 having a relatively smaller radius. A top surface 216 and a bottom surface 218 extend from either side of the airfoil batts 210 from the leading edge 212 to the trailing edge 214. The airfoil shape can be similar in cross-section to that of an airplane wing or the like. Each of the airfoil batts 210 includes internal core regions 215 for holding sound deadening material such as fiber glass or similar material known to those skilled in the art.

In some forms, a surface area of the top surface 216 is different from the surface area of the bottom surface 218. Each core is surrounded by a porous material wrapped around the outer walls to facilitate noise attenuation. In one form, the airfoil batts 210 can be arranged in a first column 223 and a second column 225 positioned side by side within the batt carrier 200. In other forms, the airfoil batts 210 may only include one column, and in yet other forms, the airfoil batts 210 may be aligned in three or more columns within the batt carrier 200. The airfoil batts 210 are arranged such that a space 222 is formed between adjacent airfoil batts 210 so as to provide a flow path for air 224 to enter into the housing 150 (see FIG. 2). Noise represented by arrow 226 is transmitted through the same space 222, however the shape and form of the airfoil batts 210 minimize or attenuates the noise level relative to the prior art brick shaped batts that are shown in FIG. 3. The airfoil batts 210 can be positioned so that they are substantially aligned in a horizontal direction represented by line 230, however in other forms the airfoil batts 210 may be variably positioned at different pitch angles defined by the angle between line 230 and dash line 232. The pitch angle can be a positive or negative (pitching upward or downward) relative to the horizontal line 230. Each airfoil batt 210 can be pivotbly connected to the batt carrier 200 as would be understood by one skilled in the art. Further, the airfoil batts 210 can move in a vertical direction and vary the space 222 between the airfoil batts 210.

In some forms, the airfoil batts 210 may include a support rod 240 connected to a plurality of the airfoil batts 210 along column 223 and/or column 235. The support rod 240 may be used to connect the airfoil batts 210 together within the batt carrier 200. In some forms, the pitch angle of the airfoil batts 210 can be varied within the batt carrier 200 after initial assembly in order to optimize the direction of air flow streamlines entering the housing 150 to enhance cooling and/or reduce the noise output from air turbulence and the compressor system 10.

In one aspect, the present disclosure includes a housing for a compressor comprising a top wall; a bottom wall; one or more side walls extending between the top wall and the bottom wall; a vent region formed in one of the top, bottom or side walls; a batt carrier associated with the vent region; and a plurality of airfoil batts positioned within the batt carrier.

In refining aspects, the airfoil batts are positioned in a column with a space between each adjacent pair of airfoil batts; the airfoil batts are positioned in two or more columns within the batt carrier; the airfoil batts are formed from a sound suppression material; the sound suppression material includes a fiberglass core and an outer fabric wrap; a location of airfoil batts are movable and the space between adjacent airfoils is variable; a pitch angle of the airfoil batts is variable; a rod connected to a column of airfoil batts; one of a fan or a blower in fluid communication with the vent region of the housing; an area of a top surface of the airfoil batts is different from an area of the bottom surface.

In another aspect, the present disclosure includes an inlet for a compressor housing comprising a batt carrier having a top wall, bottom wall and opposing side walls; opposing batt receiving slots extending from each of the side walls of the batt carrier; and an airfoil shaped batt corrected with the opposing receiving slots of the carrier.

In refining aspects, the batt carrier includes a plurality of receiving slots extending along each of the sidewalls; a plurality of airfoil shaped batts positioned in a column within the plurality of receiving slots on the carrier; a plurality of airfoil shaped batts positioned in two or more columns within the plurality of receiving slots on the carrier; each airfoil shaped batt is formed from a noise suppression material; a fan or blower in fluid communication with inlet of the compressor housing; the pitch angle of the airfoil shaped batt is variable relative to the inlet; the space between adjacent airfoil shaped batts is variable.

In another aspect, the present disclosure includes a method comprising positioning a batt carrier having a plurality of airfoil batts within an inlet region of a housing; flowing airflow through openings between adjacent airfoil batts; cooling internal portions of the housing with the airflow; and suppressing noise emitted through the inlet region with the airfoil batts. In refining aspects, the airfoil batts are formed with sound suppression material.

While the application has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the applications are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the application, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.

Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. 

What is claimed is:
 1. A housing for a compressor comprising: a top wall; a bottom wall; one or more side walls extending between the top wall and the bottom wall; a vent region formed in one of the top, bottom or side walls; a batt carrier associated with the vent region; and a plurality of airfoil batts positioned within the batt carrier.
 2. The housing of claim 1, wherein the airfoil batts are positioned in a column with a space between each adjacent pair of airfoil batts.
 3. The housing of claim 2, wherein the airfoil batts are positioned in two or more columns within the batt carrier.
 4. The housing of claim 1, wherein the airfoil batts are formed from a sound suppression material.
 5. The housing of claim 4, wherein the sound suppression material includes a fiberglass core and an outer fabric wrap.
 6. The housing of claim 2, wherein a location of airfoil batts are movable and the space between adjacent airfoils is variable.
 7. The housing of claim 1, wherein a pitch angle of the airfoil batts is variable.
 8. The housing of claim 1 further comprising a rod connected to a column of airfoil batts.
 9. The housing of claim 1 further comprising one of a fan or a blower in fluid communication with the vent region of the housing.
 10. The housing of claim 1, wherein an area of a top surface of the airfoil batts is different from an area of the bottom surface.
 11. An inlet for a compressor housing comprising: a batt carrier having a top wall, bottom wall and opposing side walls; opposing batt receiving slots extending from each of the side walls of the batt carrier; and an airfoil shaped batt corrected with the opposing receiving slots of the carrier.
 12. The inlet of claim 11, wherein the batt carrier includes a plurality of receiving slots extending along each of the sidewalls.
 13. The inlet of claim 12 further comprising a plurality of airfoil shaped batts positioned in a column within the plurality of receiving slots on the carrier.
 14. The inlet of claim 12 further comprising a plurality of airfoil shaped batts positioned in two or more columns within the plurality of receiving slots on the carrier.
 15. The inlet of claim 11, wherein each airfoil shaped batt is formed from a noise suppression material.
 16. The inlet of claim 11 further comprising a fan or blower in fluid communication with inlet of the compressor housing.
 17. The inlet of claim 11, wherein the pitch angle of the airfoil shaped batt is variable relative to the inlet.
 18. The inlet of claim 11, wherein the space between adjacent airfoil shaped batts is variable.
 19. A method comprising: positioning a batt carrier having a plurality of airfoil batts within an inlet region of a housing; flowing airflow through openings between adjacent airfoil batts; cooling internal portions of the housing with the airflow; and suppressing noise emitted through the inlet region with the airfoil batts.
 20. The method of claim 19, wherein the airfoil batts are formed with sound suppression material. 